Collapsible pattern

ABSTRACT

An insulating structure for an appliance including a first panel, a second panel coupled to the first panel, wherein the first and second panels define a cavity, an insulation material disposed within the cavity, at least one central flattening portion of the first and second panels, the at least one central flattening portion defining an enlarged area of the cavity in a rest state and having deflection control features, and structural reinforcements defined by the deflection control features of the at least one central flattening portion.

CROSS-REFERENCE TO RELATED APPLICATION

The present application is a divisional of U.S. patent application Ser.No. 16/417,804 filed May 21, 2019, entitled COLLAPSIBLE PATTERN, theentire disclosure of which is hereby incorporated herein by reference.

BACKGROUND OF THE DISCLOSURE

The present disclosure generally relates to an insulating structure, andmore specifically, to a collapsible pattern for an insulating structure.

SUMMARY OF THE DISCLOSURE

According to one aspect of the present disclosure, an insulatingstructure for an appliance includes a first panel and a second panelcoupled to the first panel. The first and second panels define a cavity.An insulation material is disposed within the cavity. The insulatingstructure also includes at least one central flattening portion of thefirst and second panels. The at least one central flattening portiondefines an enlarged area of the cavity in a rest state and includesdeflection control features. In addition, structural reinforcements aredefined by the deflection control features of the at least one centralflattening portion.

According to another aspect of the present disclosure, an applianceincludes an at least one first panel and an at least one second panel.The at least one first and second panels are coupled to define astructural member. A cavity is defined between the at least one firstand second panels, and further an at least partial vacuum is definedwithin the cavity. In addition, insulation materials are disposedbetween the at least one first and second panels. Further, the applianceincludes a central flattening portion of each of the at least one firstand second panels, and structural reinforcements proximate the centralflattening portion.

According to yet another aspect of the present disclosure, a method offorming a structural cabinet for an appliance includes forming a centralflattening portion of each of a first panel and a second panel,disposing a plurality of structural reinforcements proximate curvedportions of the central flattening portions of the first and secondpanels, coupling the first panel to the second panel to define a cavitytherebetween, disposing an insulation material within the cavity, theinsulation material filling the cavity. Gas is expressed from the cavityto define an at least partial vacuum within the cavity. The centralflattening portions and the plurality of structural reinforcements areutilized to deflect vacuum bow. The cavity is sealed, wherein the firstand second panels are positioned to oppose an inward compressive forcesuch that the central flattening portions of the first and second panelscompress to maintain a consistent distance between the first panel andthe second panel.

These and other features, advantages, and objects of the presentdisclosure will be further understood and appreciated by those skilledin the art by reference to the following specification, claims, andappended drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

In the drawings:

FIG. 1 is a front perspective view of an appliance of the presentdisclosure;

FIG. 2 is a top perspective view of an insulated structural cabinet ofthe present disclosure;

FIG. 3 is a side elevational view of an insulating structure of thepresent disclosure;

FIG. 4 is a side elevational view of the insulating structure of thepresent disclosure;

FIG. 5 is a top perspective view of an insulated panel of the presentdisclosure;

FIG. 6 is a top perspective view of the insulated panel of the presentdisclosure;

FIG. 7 is a cross-sectional view of the insulating structure of FIG. 3 ,taken along the line VII-VII, in a rest state of the present disclosure;

FIG. 8 is a cross-sectional view of the insulating structure of FIG. 7 ,in an expressed state of the present disclosure;

FIG. 9 is a schematic view of a stabilizing geometry in the rest stateof the present disclosure;

FIG. 10 is a schematic cross-sectional view of the stabilizing geometryof FIG. 9 , taken along the line X-X, in the rest state of the presentdisclosure;

FIG. 11 is a schematic view of the stabilizing geometry in the expressedstate of the present disclosure;

FIG. 12 is a schematic cross-sectional view of the stabilizing geometryof FIG. 11 , taken along the line XII-XII, in the expressed state of thepresent disclosure;

FIG. 13 is a schematic view of two stabilizing geometries in the reststate of the present disclosure;

FIG. 14 is a schematic view of the two stabilizing geometries in theexpressed state of the present disclosure; and

FIG. 15 is a flow diagram of a method of forming a structural cabinetfor an appliance of the present disclosure.

The components in the figures are not necessarily to scale, emphasisinstead being placed upon illustrating the principles described herein.

DETAILED DESCRIPTION

The present illustrated embodiments reside primarily in combinations ofmethod steps and apparatus components related to an insulatingstructure. Accordingly, the apparatus components and method steps havebeen represented, where appropriate, by conventional symbols in thedrawings, showing only those specific details that are pertinent tounderstanding the embodiments of the present disclosure so as not toobscure the disclosure with details that will be readily apparent tothose of ordinary skill in the art having the benefit of the descriptionherein. Further, like numerals in the description and drawings representlike elements.

For purposes of description herein, the terms “upper,” “lower,” “right,”“left,” “rear,” “front,” “vertical,” “horizontal,” and derivativesthereof shall relate to the disclosure as oriented in FIG. 1 . Unlessstated otherwise, the term “front” shall refer to the surface of theelement closer to an intended viewer, and the term “rear” shall refer tothe surface of the element further from the intended viewer. However, itis to be understood that the disclosure may assume various alternativeorientations, except where expressly specified to the contrary. It isalso to be understood that the specific devices and processesillustrated in the attached drawings, and described in the followingspecification are simply exemplary embodiments of the inventive conceptsdefined in the appended claims. Hence, specific dimensions and otherphysical characteristics relating to the embodiments disclosed hereinare not to be considered as limiting, unless the claims expressly stateotherwise.

The terms “including,” “comprises,” “comprising,” or any other variationthereof, are intended to cover a non-exclusive inclusion, such that aprocess, method, article, or apparatus that comprises a list of elementsdoes not include only those elements but may include other elements notexpressly listed or inherent to such process, method, article, orapparatus. An element proceeded by “comprises a . . . ” does not,without more constraints, preclude the existence of additional identicalelements in the process, method, article, or apparatus that comprisesthe element.

Referring to FIGS. 1-15 , reference numeral 10 generally designates anappliance including an insulating structure 12. The insulating structure12 includes a first panel 14 and a second panel 16, where the first andsecond panels 14, 16 are coupled together to define a cavity 18 in whichan insulation material 20 is disposed. Additionally, the first andsecond panels 14, 16 include at least one central flattening portion 22,which defines an enlarged area 24 of the cavity 18 in a rest state 26and includes deflection control features 28. Further, structuralreinforcements 30 are defined by the deflection control features 28 ofthe at least one central flattening portion 22.

Referring again to FIGS. 1-8 , the insulating structure 12 may be usedas an insulation member for, as a non-limiting example, a door 50 of theappliance 10. Additionally or alternatively, the first and second panels14, 16 may define a structural member 52, which may include either aninsulated structural cabinet 54 or an insulated panel 56. According tovarious examples, the first and second panels 14, 16 of the insulatingstructure 12 are contemplated to be an at least one first panel 14 andan at least one second panel 16. Thus, a plurality of panels 62, mayform a liner 64, or inner structure, and a wrapper 66, or outerstructure, of the insulated structural cabinet 54. Said another way,multiple first and second panels 14, 16 may form the liner 64 and thewrapper 66 of the insulated structural cabinet 54. The first and secondpanels 14, 16 may be a metallic material that may at least partiallyresist deflecting, bowing, bending, or other forms of compression thatmay be caused by an inward compressive force 68 that may be exerted whenan at least partial vacuum 70 is defined within the cavity 18.

Further, an opening 80 is defined by the liner 64 and may further bedefined as a first opening 82 and a second opening 84 separated by amullion 86. The opening 80 may receive the appliance 10 such that theinsulating structure 12 encases the appliance 10. In such construction,it is generally contemplated that the insulated structural cabinet 54may be used. Each of the first and second openings 82, 84 is alsodefined by a trim breaker 88. The trim breaker 88 may provide structuralsupport for the liner 64 and wrapper 66 and to form the insulatedstructural cabinet 54. Additionally, apertures 90 may be defined on thewrapper 66 adjacent the mullion 86 and configured to attach with theappliance 10. Accordingly, the central flattening portion 22 may curvearound the apertures 90. This curved configuration may also serve tocontrol the vacuum bow of the central flattening portion 22 by providinga structural reinforcement 30 where it would otherwise be a straightedge 116 of the central flattening portion 22.

In forming the structural member 52, the liner 64 may be positionedadjacent within the wrapper 66 thus partially defining the cavity 18 andboth of which may be coupled to the trim breaker 88 to fully define thecavity 18 in which the insulation material 20 is disposed. Theinsulation material 20 may be a carbon-based powder; however, it isgenerally contemplated that other standard insulation material 20 may beused; such materials are described more fully below. The insulationmaterial 20 may be generally compressible such that the insulationmaterial 20 provides minimal structural support during evacuation of thecavity 18. In other words, the inward compressive force 68 may beslightly resisted by the insulation material 20, but ultimately, vacuumbowing may occur despite the use of certain insulation material 20.

Additionally, the at least partial vacuum 70 is defined within thecavity 18 once the evacuation process has occurred and the insulatingstructure 12 is in the expressed state 100. As such, the at leastpartial vacuum 70 defines a pressure differential 96 between an exteriorportion 98 of the insulating structure 12 and the cavity 18.Furthermore, the inward compressive force 68 is defined by the pressuredifferential 96. The inward compressive force 68 may cause the centralflattening portion 22 of the insulating structure 12 to result in avacuum bow or a deflection, as discussed above. The vacuum bow resultsin the central flattening portion 22 decreasing the size of the cavity18 as a result of the wrapper 66 and the liner 64 compressing into thecavity 18. For example, in traditional insulating structures 12, vacuumbow may occur to such an extent generally ranging from about 10millimeters to about 18 millimeters, or more, from the rest state 26 toan expressed state 100, which may result in a depth or thickness of thecavity 18 that is irregular across the insulating structure 12.

As illustrated in FIG. 2 , the wrapper 66 includes the centralflattening portion 22 defined by an inner perimeter 110 and an outerperimeter 112, which delineate at least one curved portion 114 definingthe structural reinforcements 30. Additionally, the curved portion 114may have a substantially scallop-shape, which may help to resist vacuumbow based on the shape, as described in more detail below. By way ofexample, and not limitation, when the insulating structure 12 undergoesthe inward compressive force 68, the structural reinforcements 30 helpresist and/or control biasing, bowing, or other deflection of thecentral flattening portion 22. The resistance of the biasing by thestructural reinforcements 30 may be aided by the deflection controlfeatures 28 and stabilizing geometries 118 utilizing opposingly adjacentforces 120 of the stabilizing geometries 118. Said another way, upontransition from the rest state 26 to the expressed state 100, thestabilizing geometries 118 of the structural reinforcements 30 and thedeflection control features 28 stabilize and control the deflection ofthe central flattening portion 22.

Referring again to FIGS. 9-14 , for purposes of illustration anddepiction, the stabilizing geometries 118 of the central flatteningportion 22 have been exaggerated to show detail, but the generalconstruction of the stabilizing geometries 118 may generally be asdepicted. Each stabilizing geometry 118 may have a generallyfrustoconical shape including a short arc 130 and a long arc 132.Additionally, as the gases are expressed from the cavity 18, thestabilizing geometry 118 will undergo tension forces 134. Due to theshape of the stabilizing geometry 118, the tension forces 134, uponevacuation of the cavity 18, will press against the deflection controlfeatures 28. These tension forces 134 will tend to flatten thestabilizing geometry 118. In turn, the overall inward compressive forceincludes a biasing force 136 that may act upon the short and long arcs130, 132. The biasing force 136 may act upon an inner portion 138 of theshort arc 130 and an outer portion 140 of the long arc 132. Generally,the central flattening portion 22 includes a high portion 142 and a lowportion 144, where the high portion 142 undergoes a stronger tensionforce 134 than does the low portion 144. Moreover, where a singlestabilizing geometry 118 is used, the short arc 130 may be generallylocated on the high portion 142 of the central flattening portion 22,and the long arc 132 may be generally located on the low portion 144 ofthe central flattening portion 22.

It is generally contemplated that when there are multiple stabilizinggeometries 118, the long arc 132 may alternatively be located at thehigh portion 142 and the short arc 130 may be located at the low portion144 of the central flattening portion 22. For example, as shown in FIG.13 , a first stabilizing geometry 146, including a first short arc 148and a first long arc 150, is adjacent a second stabilizing geometry 152,including a second short arc 154 and a second long arc 156. Accordingly,as illustrated, the first short arc 148 is adjacent the second long arc156 on the high portion 142 of the central flattening portion 22, andthe first long arc 150 is adjacent the second short arc 154 on the lowportion 144 of the central flattening portion 22.

As the insulating structure 12 transitions into the expressed state 100,the tension forces 134 push against the deflection control features 28of the stabilizing geometry 118. The tension force 134 along the shortarc 130 is a large tension force 158 whereas the tension force 134 alongthe long arc 132 is a small tension force 160. Thus, as illustrated inFIG. 14 , the large tension force 158 of the first short arc 148 opposesthe small tension force 160 of the second long arc 156 as the insulatingstructure 12 transitions from the rest state 26 to the expressed state100 (FIG. 14 ). Further, as illustrated in FIGS. 10 and 12 , the biasingforces 136 are stronger at the high portion 142 than at the low portion144. The opposingly adjacent forces 120 meet at a compression area 122that resists the downward deflection of the adjacent deflection controlfeatures 28.

In addition, the stabilizing geometries 118 use the opposingly adjacentforces 120 to prevent flattening of the central flattening portion 22 toa co-planar position with respect to the outer edges of the first andsecond panels 14, 16. By preventing the co-planar position, the centralflattening portion 22 is prevented from collapsing inward, beyond theco-planar position. Also, in reference to a single stabilizing geometry118, the short arc 130 may undergo a large biasing force 162, as theshort arc 130 may be positioned relative the high portion 142 of thecentral flattening portion 22. In further reference to a singlestabilizing geometry 118, the long arc 132 may correspondingly undergo asmall biasing force 164, as the long arc 132 may be positioned relativethe low portion 144 of the central flattening portion 22.

Thus, each stabilizing geometry 118 may have a different shape to braceagainst the opposingly adjacent forces 120 of the neighboringstabilizing geometry 118 to define the compression arc that resistsinward deflection. For example, the stabilizing geometries 118 may havea frustoconical shape, a rectangular shape, an arcuate trapezoidalshape, or other geometric shapes known in the art. The opposinglyadjacent forces 120 may include either the large tension force 158, thesmall tension force 160, or both. These opposingly adjacent forces 120of the stabilizing geometries 118 may substantially offset the biasingforce 136 when the insulating structure 12 enters the expressed state100 (FIG. 8 ). Further, the deflection control features 28 form anoutline 166 of the stabilizing geometries 118 such that the stabilizinggeometries 118 may be defined by the deflection control features 28. Forexample, the deflection control features 28 of the first stabilizinggeometry 146 may also define the second stabilizing geometry 152. Saidanother way, the outline 166 defined by the deflection control features28 of the first stabilizing geometry 146 may share a deflection controlfeature 28 of the second stabilizing geometry 152.

Referring again to FIGS. 2-4 , evacuation ports 170 are depicted lateralthe outer perimeter 112 of the central flattening portion 22. Theevacuation ports 170 are used to express gases from the cavity 18forming the at least partial vacuum 70. As such, the first and secondpanels 14, 16 are drawn together and decrease the size of the cavity 18,thus forming the insulating structure 12 in the expressed state 100. Inpart to accommodate the evacuation ports 170, the curved portions 114 ofthe central flattening portion 22 may have a substantially serpentineconfiguration. For example, multiple curved portions 114 may be insequence where a first curved portion 172 has an inward curve 174 and asecond curved portion 176 has an outward curve 178, relative the centralflattening portion 22. The first and second curved portions 172, 176 mayprovide greater resistance to the vacuum bow than if the straight edge116 continued along a body length 180 of the insulating structure 12.

Alternatively, the evacuation ports 170 may be positioned centrally orin a corner 182 of the first or second panels 14, 16. Additionally, theinsulated structural cabinet 54 includes a recessed portion 184, asillustrated, below the evacuation ports 170 on at least one of theplurality of panels 62. The deflection control features 28 of therecessed portion 184 may include substantially linear stabilizinggeometries 118. The recessed portion 184 may be configured to fit aroundthe mechanical components of the appliance 10 such as, for example,motors and compressors.

In further reference to FIGS. 5 and 6 , the first and second panels 14,16 of the insulating structure 12 are coupled to the trim breaker 88,which helps to define the cavity 18. Additionally, the first and secondpanels 14, 16 may include corner edges 190 configured to receivefasteners 192. These fasteners 192 typically connect the insulated panel56 with the appliance 10. For example, the insulated panel 56 may beused in the door 50 of the appliance 10 and the fasteners 192 mayprovide the coupling means between the door 50 and the insulated panel56. The insulated panel 56, as illustrated in FIG. 6 , includes fourcurved portions 114. It is generally contemplated that the curvedportions 114 have a substantially scallop-shape such that, by way ofexample and not limitation, three structural reinforcements 30, eachwith three different stabilizing geometries 118, may comprise the curvedportions 114. Alternatively, as shown in FIG. 5 , in order toaccommodate the evacuation port 170, the insulated panel 56 may includethree generally scallop-shaped curved portions 114 and one diagonalportion 194 having different stabilizing geometries 118. In one example,the inner and outer perimeters 110, 112 of the central flatteningportion 22 may have a narrow width 196; however, it is also contemplatedthat the inner and outer perimeters 110, 112 may have a wide width 198.

Referring again to FIGS. 7 and 8 , the insulating structure 12 is shownin the rest state 26 in FIG. 7 and in the expressed state 100 in FIG. 8. It is generally contemplated that the structural reinforcements 30substantially maintain the structural integrity of the insulatingstructure 12 such that the central flattening portion 22 deflects in acontrolled manner. For example, the dashed line illustrated in FIG. 7indicates a desired deflection 200 of the central flattening portion 22such that the insulating structure 12 meets a desired flatness ofapproximately one millimeter of height away from co-planar. Although thecavity 18 is filled with the insulation material 20, it is thestructural reinforcements 30, the stabilizing geometries 118, and thedeflection control features 28 of the curved portions 114 thatultimately allow the central flattening portion 22 to resist the vacuumbow.

By way of example, and not limitation, the curved portions 114 also helpcontrol vacuum bow within approximately two millimeters of deflection.Additionally, the insulating structure 12 may then be evacuated in acontrolled and uniform manner such that the central flattening portions22 of the first and second panels 14, 16 typically deflect in unison.This may be accomplished by including the varying stabilizing geometries118. The shape of the stabilizing geometries 118 may allow for thecontrolled vacuum bow, as discussed in more detail above. For example,when expressing gases from the cavity 18, the central flattening portion22 is typically drawn inward toward the cavity 18, resulting in vacuumbow. When this occurs, the biasing forces 136 of each of the opposinglyadjacent stabilizing geometries 118 oppose the inward compressive force68 from the central flattening portion 22. For example, the deflectioncontrol features 28 of the stabilizing geometries 118 may disperse thebiasing forces 136 and, as a result, the stabilizing geometries 118compress in a controlled manner.

Referring now to FIGS. 1-15 , having described various aspects of theinsulating structure 12, a method 300 is disclosed for forming astructural cabinet 54 for an appliance 10. According to the method 300,central flattening portions 22 of a first panel 14 and a second panel 16are formed (step 302). A plurality of structural reinforcements 30 aredisposed proximate curved portions 114 of the central flatteningportions 22 of the first and second panels 14, 16 (step 304). Theplurality of structural reinforcements 30 may also be defined by thecurved portions 114. According to the method 300, the first and secondpanels 14, 16 are coupled to partially define a cavity 18 therebetween(step 306). The cavity 18 may further be defined by a trim breaker 88coupled to the first and second panels 14, 16. An insulation material 20is then disposed within the cavity 18 such that the insulation material20 fills the cavity 18 space (step 308).

Gas is then expressed from the cavity 18 to define an at least partialvacuum 70 within the cavity 18 (step 310). Accordingly, stabilizinggeometries 118 of the structural reinforcements 30 are partially smoothsuch that the stabilizing geometries 118 are less perceptible (step312). The central flattening portion 22 along with the plurality ofstructural reinforcements 30 are then used to deflect vacuum bow (step314). The first and second panels 14, 16 are then positioned to opposean inward compressive force 68 such that the central flattening portions22 of the first and second panels 14, 16 compress to maintain asubstantially consistent distance between the first panel 14 and thesecond panel 16 when the cavity 18 is sealed (step 316).

According to the various examples, the insulating structure 12 can beused in various appliances 10 that can include, but are not limited to,refrigerators, freezers, coolers, ovens, dishwashers, laundryappliances, water heaters, and other similar appliances and fixtureswithin household and commercial settings. Additionally, the insulationmaterials 32 can be a free-flowing material that can be poured, blown,compacted or otherwise disposed within the cavity 18. This free-flowingmaterial can be in the form of various silica-based materials, such asfumed silica, precipitated silica, nano-sized and/or micro-sided aerogelpowder, rice husk ash powder, perlite, glass spheres, hollow glassspheres, cenospheres, diatomaceous earth, combinations thereof, andother similar insulating particulate material.

According to another aspect of the present disclosure, an insulatingstructure for an appliance includes a first panel, a second panelcoupled to the first panel, wherein the first and second panels define acavity, an insulation material disposed within the cavity, at least onecentral flattening portion of the first and second panels, the at leastone central flattening portion defining an enlarged area of the cavityin a rest state and having deflection control features, and structuralreinforcements defined by deflection control features of the at leastone central flattening portion.

According to another aspect of the present disclosure, the at least onecentral flattening portion includes a first central flattening portionon the first panel and a second central flattening portion of the secondpanel.

According to still another aspect of the present disclosure, thestructural reinforcements include stabilizing geometries.

According to another aspect of the present disclosure, the at least onecentral flattening portion includes a plurality of scallop-shapedportions.

According to yet another aspect of the present disclosure, thestructural reinforcements are generally scallop-shaped.

According to another aspect of the present disclosure, the structuralreinforcements are configured to stabilize the at least one centralflattening portion in an expressed state.

According to another aspect of the present disclosure, the at least onecentral flattening portion is approximately 1 millimeter offset from aremainder of the first and second panels in an expressed state.

According to still another aspect of the present disclosure, the coupledfirst and second panels define a structural member.

According to another aspect of the present disclosure, an applianceincludes an at least one first panel, an at least one second panel,wherein the at least one first and second panels are coupled to define astructural member, a cavity defined between the at least one first andsecond panels, and further wherein an at least partial vacuum is definedwithin the cavity, insulation materials disposed between the at leastone first and second panels, a central flattening portion of each of theat least one first and second panels, and structural reinforcementsproximate the central flattening portion.

According to another aspect of the present disclosure, multiple firstpanels are coupled to multiple second panels to further define astructural cabinet.

According to yet another aspect of the present disclosure, the centralflattening portion further includes curved portions, wherein the curvedportions are generally scallop-shaped.

According to another aspect of the present disclosure, thescallop-shaped curved portions are configured to absorb an inwardcompressive force generated by the partial vacuum.

According to another aspect of the present disclosure, the structuralreinforcements further include stabilizing geometries, wherein thestabilizing geometries are configured to resist deflection to aco-planar state.

According to still another aspect of the present disclosure, thestabilizing geometries are substantially imperceptible upon expressinggas from the cavity.

According to another aspect of the present disclosure, the centralflattening portion of the at least one first panel and the centralflattening portion of the at least one second panel are configured tocompress such that the central flattening portions are flush with the atleast one first and the at least one second panels, respectively.

According to another aspect of the present disclosure, the structuralreinforcements are substantially imperceptible upon expressing gas fromthe cavity.

According to yet another aspect of the present disclosure, the centralflattening portion of each of the at least one first panel and the atleast one second panel is a scallop-shape.

According to another aspect of the present disclosure, the at least onefirst panel and the at least one second panel further include corneredges, and fastener portions proximate the corner edges.

According to another aspect of the present disclosure, a method offorming a structural cabinet for an appliance including the steps offorming a central flattening portion of each of a first panel and asecond panel, disposing a plurality of structural reinforcementsproximate curved portions of the central flattening portions of thefirst and second panels, coupling the first panel to the second panel todefine a cavity therebetween, disposing an insulation material withinthe cavity, the insulation material filling the cavity, expressing gasfrom the cavity to define an at least partial vacuum within the cavity,utilizing the central flattening portions and the plurality ofstructural reinforcements to deflect vacuum bow, and sealing the cavity,wherein the first and second panels are positioned to oppose an inwardcompressive force such that the central flattening portions of the firstand second panels compress to maintain a consistent distance between thefirst panel and the second panel.

According to still another aspect of the present disclosure, the step ofexpressing gas from the cavity further includes the step of smoothingstabilizing geometries of the plurality of structural reinforcementssuch that the stabilizing geometries are substantially imperceptible.

It will be understood by one having ordinary skill in the art thatconstruction of the described disclosure and other components is notlimited to any specific material. Other exemplary embodiments of thedisclosure disclosed herein may be formed from a wide variety ofmaterials, unless described otherwise herein.

For purposes of this disclosure, the term “coupled” (in all of itsforms, couple, coupling, coupled, etc.) generally means the joining oftwo components (electrical or mechanical) directly or indirectly to oneanother. Such joining may be stationary in nature or movable in nature.Such joining may be achieved with the two components (electrical ormechanical) and any additional intermediate members being integrallyformed as a single unitary body with one another or with the twocomponents. Such joining may be permanent in nature or may be removableor releasable in nature unless otherwise stated.

It is also important to note that the construction and arrangement ofthe elements of the disclosure as shown in the exemplary embodiments isillustrative only. Although only a few embodiments of the presentinnovations have been described in detail in this disclosure, thoseskilled in the art who review this disclosure will readily appreciatethat many modifications are possible (e.g., variations in sizes,dimensions, structures, shapes and proportions of the various elements,values of parameters, mounting arrangements, use of materials, colors,orientations, etc.) without materially departing from the novelteachings and advantages of the subject matter recited. For example,elements shown as integrally formed may be constructed of multiple partsor elements shown as multiple parts may be integrally formed, theoperation of the interfaces may be reversed or otherwise varied, thelength or width of the structures and/or members or connector or otherelements of the system may be varied, the nature or number of adjustmentpositions provided between the elements may be varied. It should benoted that the elements and/or assemblies of the system may beconstructed from any of a wide variety of materials that providesufficient strength or durability, in any of a wide variety of colors,textures, and combinations. Accordingly, all such modifications areintended to be included within the scope of the present innovations.Other substitutions, modifications, changes, and omissions may be madein the design, operating conditions, and arrangement of the desired andother exemplary embodiments without departing from the spirit of thepresent innovations.

It will be understood that any described processes or steps withindescribed processes may be combined with other disclosed processes orsteps to form structures within the scope of the present disclosure. Theexemplary structures and processes disclosed herein are for illustrativepurposes and are not to be construed as limiting.

What is claimed is:
 1. An insulating structure for an appliancecomprising: a first panel; a second panel coupled to the first panel,wherein the first and second panels define a cavity; an insulationmaterial disposed within the cavity; at least one central flatteningportion of the first and second panels, the at least one centralflattening portion defining an enlarged area of the cavity in a reststate and having deflection control features; and structuralreinforcements defined by the deflection control features of the atleast one central flattening portion.
 2. The insulating structure ofclaim 1, wherein the at least one central flattening portion includes afirst central flattening portion of the first panel and a second centralflattening portion of the second panel.
 3. The insulating structure ofclaim 1, wherein the structural reinforcements include stabilizinggeometries.
 4. The insulating structure of claim 1, wherein the at leastone central flattening portion includes a plurality of scallop-shapedportions.
 5. The insulating structure of claim 1, wherein the structuralreinforcements are generally scallop-shaped.
 6. The insulating structureof claim 1, wherein the structural reinforcements are configured tostabilize the at least one central flattening portion in an expressedstate.
 7. The insulating structure of claim 1, wherein the at least onecentral flattening portion is approximately 1 millimeter offset from aremainder of the first and second panels in an expressed state.
 8. Theinsulating structure of claim 1, wherein the coupled first and secondpanels define a structural member.
 9. The insulating structure of claim1, wherein the cavity includes an at least partial vacuum that generatesan inward compressive force that is exerted on the at least one firstand second panels toward the cavity.
 10. The insulating structure ofclaim 9, wherein the central flattening portion includes a high portionand a low portion, wherein the inward compressive force of the at leastpartial vacuum biases and deflects the high portion toward a co-planarposition with respect to the low portion.
 11. The insulating structureof claim 10, wherein the structural reinforcements further comprisestabilizing geometries that are configured to resist the inwardcompressive force and resist deflection of the central flatteningportion beyond the co-planar position
 12. The insulating structure ofclaim 9, wherein upon expression of gas from the cavity, the centralflattening portion of the at least one first panel and the centralflattening portion of the at least one second panel are configured todeflect under the inward compressive force such that the centralflattening portions are flush with the at least one first and the atleast one second panels, respectively.
 13. A method of forming astructural cabinet for an appliance, the method comprising steps of:forming a central flattening portion of each of a first panel and asecond panel; disposing a plurality of structural reinforcementsproximate curved portions of the central flattening portions of thefirst and second panels; coupling the first panel to the second panel todefine a cavity therebetween; disposing an insulation material withinthe cavity, the insulation material filling the cavity; expressing gasfrom the cavity to define an at least partial vacuum within the cavity;utilizing the central flattening portions and the plurality ofstructural reinforcements to deflect vacuum bow; and sealing the cavity,wherein the first and second panels are positioned to oppose an inwardcompressive force such that the central flattening portions of the firstand second panels compress to maintain a consistent distance between thefirst panel and the second panel.
 14. The method of claim 13, whereinthe step of expressing gas from the cavity further comprises the stepof: smoothing stabilizing geometries of the plurality of structuralreinforcements such that the stabilizing geometries are substantiallyimperceptible.
 15. The method of claim 13, wherein the plurality ofstructural reinforcements include scallop-shaped curved portions thatare configured to prevent deflection of the central flattening portionbeyond a co-planar position of high and low portions of the centralflattening portions, and wherein the deflection of the scallop-shapedcurved portions absorbs the inward compressive force generated by the atleast partial vacuum to prevent the deflection of the central flatteningportion beyond the co-planar position.
 16. An insulating structure foran appliance comprising: a structural member with a cavity definedtherein, wherein the cavity defines an at least partial vacuum, whereinthe at least partial vacuum generates an inward compressive force thatis exerted on an outer surface of the structural member and toward thecavity; insulation materials disposed between the structural member; acentral flattening portion of at least one panel of the structuralmember, the central flattening portion including a high portion and alow portion, wherein the inward compressive force of the at leastpartial vacuum biases and deflects the high portion toward a co-planarposition with respect to the low portion; and structural reinforcementsdefined by the central flattening portion of the at least one panel andextending between the high portion and the low portion, the inwardcompressive force of the at least partial vacuum deflecting thestructural reinforcements and the central flattening portion toward theco-planar position, the structural reinforcements being scallop-shapedcurved portions that are configured to prevent deflection of the centralflattening portion beyond the co-planar position of the high and lowportions, wherein: the deflection of the scallop-shaped curved portionsare configured to absorb the inward compressive force generated by theat least partial vacuum to prevent the deflection of the centralflattening portion beyond the co-planar position; the structuralreinforcements further comprising stabilizing geometries that areconfigured to resist the inward compressive force and resist deflectionof the central flattening portion beyond the co-planar position; andupon expression of gas from the cavity, the central flattening portionof the at least one panel of the structural member are configured todeflect under the inward compressive force such that the centralflattening portion of the at least one panel is flush with areas of theat least one panel outside of the central flattening portion.
 17. Theappliance of claim 16, wherein the at least one panel of the structuralmember includes a plurality of first panels that are coupled to aplurality of second panels, respectively, to define a structuralcabinet.
 18. The appliance of claim 16, wherein the at least one panelfurther comprises: corner edges; and fastener portions proximate thecorner edges.
 19. The appliance of claim 16, wherein the at least onepanel of the structural member is a metallic panel.
 20. The appliance ofclaim 16, wherein the insulation materials include at least one of asilica-based material, rice husk ash powder, perlite, glass spheres,hollow glass spheres, cenospheres, and diatomaceous earth.